Product Manufacturing - How Things are Made

Teapill Manufacturing

The manufacturing of a teapill begins with the decoction of a formula at a low, precisely controlled temperature. Extractors are stainless steel, vacuum-sealed chambers, and this combination of low temperature extraction and vacuum–sealed container ensures that no active ingredients or essential oils are lost when released during the decoction process.

Essential oils are lifted up by the steam within the extractor and collected for later addition. The extracted liquid is pumped into heated condensers to further concentrate into a paste. The paste is blended with one or more powdered herbs chosen from the original formula to form a herbal dough. The dough is cut into small balls, after which a small amount of talcum (Hua shi) and activated carbon may be added for smoothness and consistency on the pill exterior. The balls are spun into our superior quality teapills, and coated with a fine layer of edible wax to for easier swallowing and to help naturally preserve freshness.

Finished batches of teapills are tested for various quality assurance parameters including active ingredient constituents, moisture content, disintegration time, heavy metals (lead, arsenic, mercury, cadmium) and microbial contamination. These tests are performed on every batch of finished product. Following extensive in–house testing, heavy metal testing on random batches is conducted again at third party accredited labs to confirm results and to ensure that our standards of purity and safety are met.

Plum Flower® Premier Quality™ Chinese Herbs

All Plum Flower® Premier Quality™ Chinese Herbs are the officially validated species as listed in the Chinese Pharmacopoeia or other government accepted Materia Medicas. Herbs are sourced from their indigenous regions, ensuring geo-authenticity and quality, and usually come to us direct from the growers and harvesting co–ops. Upon receipt, each herb is inspected to ensure correct species identification, proper maturity, and quality.

Inspection is conducted by highly trained staff using macroscopic, microscopic, and sometimes thin layer chromatography (TLC) means to confirm species. Herbs are tested also for sulfur dioxide residues and for certain pesticide residues to ensure safety and quality.

Plum Flower® Premier Quality™ Chinese Herbs are processed according to Official PRC Pharmacopoeia and Materia Medica methods to reduce toxicity, modify herb characteristics, and to enhance efficacy. Further processing may include cutting (by machine or hand), steaming, and drying. Proprietary methods have been developed to avoid the typical manner of preserving herbs with sulfur dioxide fumigation and other preservatives. The processed and prepared herbs are vacuum packaged and nitrogen injected, either in between the double bags, or into the bag if singly bagged, to naturally preserve freshness.

Finished batches of Plum Flower® Premier Quality™ Chinese Herbs are subjected to over 15 tests for quality assurance including species verification, moisture content, heavy metals (lead, arsenic, mercury, cadmium), and microbial contamination. They are also tested for certain pesticide residues. These tests are performed on every batch of finished product and can be verified and traced by the batch number on every package or bottle.

Tablet Manufacturing

The manufacturing of a tablet begins with the decoction of a formula at a low, precisely controlled temperature. Extractors are stainless steel, vacuum-sealed chambers, and this combination of low temperature extraction and vacuum–sealed container ensures that no active ingredients or essential oils are lost when released during the decoction process.

Essential oils are lifted up by the steam within the extractor and collected for later addition. The extracted liquid is pumped into heated condensers to further concentrate into a paste. The paste is blended with one or more powdered herbs chosen from the original formula to form a herbal dough. This dough is then pressed into shape with carefully controlled pressure to ensure appropriate dissolution rate and absorption time when ingested. Various excipients are also used when necessary to ensure consistent quality.

Finished batches of tablets are tested for various quality assurance parameters including active ingredient constituents, moisture content, disintegration time, heavy metals (lead, arsenic, mercury, cadmium) and microbial contamination. These tests are performed on every batch of finished product. Following extensive in–house testing, heavy metal testing on random batches is conducted again at third party accredited labs to confirm results and to ensure that our standards of purity and safety are met.

Extract Powder Manufacturing

The manufacturing of an extract powder begins with the decoction of a single herb or formula at a low, precisely controlled temperature. Extractors are stainless steel, vacuum-sealed chambers, and this combination of low temperature extraction and vacuum–sealed container ensures that no active ingredients or essential oils are lost when released during the decoction process.

Essential oils are lifted up by the steam within the extractor and collected for later addition. The extracted liquid is pumped into heated condensers to evaporate excess water until the extract reaches an ideal density. The concentrated liquid is pumped to a spray dryer, where the liquid is atomized into a mist and introduced into the spray–drying tower, within which is a helix of hot air. As the herbal mist makes contact with the heated air, the water content evaporates, and the solids in the extract become small particles and spiral to the bottom of the tower in a matter of seconds.

Individual herbs can vary significantly in the amount of dissolved solids they yield during extraction. Many do not have the needed substance to form a powder, and our single herb extract powders contain a pharmaceutical-grade, non-GMO corn-based dextrin when necessary.

It is important to note that our formula extract powders do not contain any excipients. They are spray-dried directly from the condensed herbal decoction, and the resulting powder is the natural yield of the formulation

Individual herb extract standards are set by a small committee within the Quality Control Department, which has developed optimal production guidelines for each herb or formula by creating micro-batches in a laboratory environment.

Each batch of finished powder is tested to our quality assurance standards for moisture content, dissolution, heavy metals (lead, arsenic, mercury, cadmium) and microbial contamination.

Following extensive in–house testing, heavy metal testing on random batches is routinely conducted at third party labs to confirm results and to ensure that our standards of purity and safety are met.

Capsule Manufacturing

Generally, capsule products are made by compacting powders or granules into gelatin or vegetarian capsules. A fine selection of Chinese herbal supplements is available in the Plum Flower® Capsule line. All capsules used are vegetarian and the ingredients are natural yield extract powder or a combination of natural yield and standardized extracts.

Infusion Manufacturing

Infusions are herbal extracts of single herbs or formulas manufactured similarly to extract powders, but made into a granule rather than powder. Infusions contain sugar, in amounts ranging from 7–40% depending upon the formula.

This medium makes them more palatable, easy to administer, and simple to reconstitute into a tea when mixed with hot water. Many of the infusions offered by Mayway come from the Guangzhou Qixing Pharmaceutical Co. Ltd., an internationally GMP certified manufacturer and the proud producer of Star Ring® Brand.

External Use Manufacturing

Mayway distributes a selection of plasters, liniments, ointments and creams. However, as we do not import these products directly, manufacturing information is limited to what is printed on or contained with the product itself.

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